The present invention is directed to the seasoning of food product, in particular but not limited to, marinating meat product.

Background to the Invention

In the food industry, there is large consumer demand for pre-packaged and pre- flavoured food products, for example marinated chicken that can be cooked directly from the packet with minimal input from the consumer.

Food product is typically marinated (or flavoured with other seasoning) using a tumble drum. Food product such as chicken is supplied continuously to the tumble drum, which is inclined such that items of food product are supplied to an upper opening of the drum and exit the drum from a lower opening. The marinade or other seasoning is supplied to the tumble drum together with the items of food product.

The tumble drum rotates so that the food product mixes with the marinade or other seasoning within the drum and is thereby flavoured or tenderised as required. The food product moved down the incline from the upper opening and exits the drum through the lower opening. The flavoured food product is then weighed, batched, packaged and distributed as is known in the art. However, there are a number of disadvantages of using such a tumble drum. Firstly, the rotation of the drum causes food product to move about in a manner that can cause bruising and other undesirable damage. Secondly, as the individual items of food product move down the incline and exit the drum at different times, it is difficult to control the amount of mixing of individual items of food product with the marinade or seasoning. This can cause some items of food product to be "over-flavoured" and, conversely, some to be "under flavoured".

A further problem is that it is not possible to keep individual items of food product within a batch together and separate from other batches within the drum without substantially slowing throughput. As a result, individual items of food product need to be marinated or otherwise seasoned before being weighed and sorted into batches. As the food products are subsequently weighed having been marinated or otherwise seasoned, the amount of pre-flavoured food product being packaged and distributed is difficult to monitor and control, as the amount of flavouring has to be taken into account. This is a particular problem with meat, which is priced on a per-weight basis.

Alternative seasoning apparatus are known, for example, from US 2004/0244681 A1 , and GB 856763 A which disclose an Archimedes screw that is used to gradually move food product along a trough in order to coat it in seasoning. The steady movement of the Archimedes screw has been found to be ineffective and inefficient for coating food product. There is therefore a requirement for a seasoning apparatus that overcomes these problems.

Summary of the Invention

In accordance with the present invention, apparatus for seasoning food product comprises:

a supply part operable to receive a food product to be seasoned;

a discharge part spaced from the supply part operable to discharge seasoned food product;

a plurality of sections arranged between said supply part and discharge part operable to contain seasoning product when in use; and,

transfer means operable to transfer food product from the supply part to the discharge part through each of said plurality of sections when in use, such that the food product is substantially coated with seasoning product. With this invention, processing of the food product is achieved in a much more controllable manner and yet the transfer means achieves a good coating of the food product with seasoning. Preferably, the transfer means is further operable to turn the food product at least once between the supply part and the discharge part. This turning or tumbling action increases the ability to achieve full seasoning of the product but in a controlled manner.

In the preferred embodiment, the plurality of sections are provided by a plurality of substantially parallel plates mounted on an elongate rotatable axle, each section being defined by first and second adjacent plates, the first plate being proximal to the supply part and the second plate being proximal to the discharge part; wherein each plate comprises an aperture such that food product may be transferred from one section to an adjacent section closer to the discharge part; and further wherein, each section comprises a corresponding guide member extending between the first and second plates, at an angle offset from a direction of elongation of the axle such that, on rotation of the axle, food product is transferred by the guide member from the supply part to the discharge part through each of the plurality of sections.

This embodiment is particularly advantageous since all the sections are provided about a single rotatable axle leading to a compact construction which is easily operable. It is, however, envisaged that the sections could be provided separately and be individually actuated. Furthermore, although each section could be defined by its own pair of first and second parallel plates, conveniently the first plate of one section defines the second plate of an adjacent section. We also provide a food packaging system comprising an in-line arrangement of a weigher operable to weigh batches of food products; a seasoning apparatus according to the first aspect of the invention; and a packaging line for packing the seasoned food product. Brief Description of the Drawings

Embodiments of the present invention will now be described with reference to the appended drawings, in which:

Figure 1A is a side view of a food packaging system according to an embodiment of the invention; Figure 1 B is a plan view of the food packaging system according to an embodiment of the invention;

Figure 2 is a perspective view of a marinating apparatus according to a second embodiment of the invention;

Figure 3 is a cross-section of the marinating apparatus of the second embodiment along X-X';

Figure 4 is a perspective view of the axle, plates and guide members of the second embodiment of the invention;

Figure 5 is a plan view of the axle, plates and guide members of the second embodiment of the invention;

Figure 6A is a cross-section of the marinating apparatus of the second embodiment along Y-Y', and;

Figure 6B is a cross-section of the marinating apparatus of the second embodiment along Y-Y' with plate 1121 removed.

Detailed Description

Figure 1A illustrates a side view of an in-line food packaging system according to an embodiment of the invention. Figure 1 B illustrates a plan view of said packaging system. For consistency and clarity, the following description will refer to 500g batches of four chicken breasts to be marinated and packaged, although it will be appreciated that the present invention can be used to marinade or season or flavour any food product, in different batch sizes and weights.

Individual chicken breasts are introduced to a multihead weigher (such as combination weigher model CCW-R220W manufactured by Ishida Europe Limited) along infeed conveyor 2. 500g batches of four chicken breasts are weighed by the weigher 1 as is known in the art, and the portions are deposited onto outfeed conveyor 4 through timing hopper 3. The batches are schematically illustrated in Figure 1 A at 8a and 8b.

As seen in Figure 1 B, the food packaging system further comprises a packaging line 10 laterally spaced from and substantially parallel to the outfeed conveyor 4. Two elongate and substantially parallel marinating apparatuses 100, 200 extend between the outfeed conveyor 4 and the packaging line 10. In the view of Figure 1 , batch 8a will be transported from outfeed conveyor 4 to packaging line 10 by marinating apparatus 100, and batch 8b will be transported from the outfeed conveyor 4 to the packaging line 10 by marinating apparatus 200. Each marinating apparatus comprises a supply part at the end proximal to the outfeed conveyor 4, and the chicken portions fall under gravity from the outfeed conveyor 4 into the supply part of their respective marinating apparatus. Each marinating apparatus further comprises a discharge part located distal to the supply part, and in use the marinating apparatuses 100, 200 transport chicken batches from the supply part to the discharge part, whilst applying marinade product. This will be explained in more detail below.

The discharge part of the marinating apparatus 100 is spaced from and vertically aligned with a first marinade timing hopper 1 1 of first distributor station 12. Batches of now-marinated chicken fall, under gravity, from the discharge part of marinating apparatus 100 into the first marinade timing hopper 1 1.

The timing hopper 11 controls the distribution of marinated chicken breast batches from the first distributor station 12 onto a batching table 17. Operators then manually package the batches into containers to be sealed.

Similarly, second marinating apparatus 200 comprises a discharge part spaced from and vertically aligned with second marinade timing hopper 13 of second distributor station 14. In the same manner as described above, batches of marinated chicken breast fall under gravity from the discharge part of second marinating apparatus 200 and into the second marinade timing hopper such that batches may be packaged into containers on batching table 17.

The packaged containers are then transported on a conveyor to sealing unit 16 where the containers are sealed. The sealed containers are subsequently distributed as necessary, for example to a supermarket or restaurant.

It will be appreciated that the food packaging system does not necessarily have to comprise two marinating apparatuses, for example it may comprise one apparatus or three or more apparatuses. The use of two or more apparatuses advantageously increases throughput of the system. Further, if different marinades are used for the first and second marinating apparatuses, two different batch types of chicken breast may be processed and packaged simultaneously.

Figure 2 shows a perspective view of a marinating apparatus 100 according to an embodiment of the invention. The marinating apparatus comprises a substantially cylindrical elongate trough 101 in which is disposed an axle 103 extending along the direction of elongation of the trough 101. The trough 101 comprises opposing end pieces 101 b and 101 a to which the axle 103 is rotatably mounted. The axle is mounted to the end piece 101 a proximal to supply part 107 via mechanical linkage 152, and mounted to the end piece 101 b proximal to the discharge part 109 via bearing 105. In use the axle is rotated by control system 150 which is connected to the axle by the mechanical linkage 152. The control system 150 controls the rotation speed of the axle 103.

The supply part 107 is defined by two opposing plates 107a and 1 12a fixed to the axle 103. Supply part plate 107a (distal from the discharge part 103) has an annular shape and plate 1 12a comprises an aperture (not visible in the view of Figure 2) through which chicken breasts can be transported from the supply part 107 to first section 1 10a. This transport is effected by guide member 1 15 and rotation of the axle 103, which will be described below. In use, chicken breasts fall under gravity from the outfeed conveyor 4 into the supply part 107 through the open top of the trough 101.

As seen in Figures 2 and 3, the marinating apparatus 100 comprises a plurality of spaced apart and substantially parallel stainless steel plates 1 12a, 112b, 1 12c, 1 12d, 1 12e, 1 12f, 1 12g, 1 12h, 1 12i, 112j, 1 12k and 1 121 mounted to the axle 103. The plates have a planar surface and are mounted such that the planar surface is in a plane perpendicular to the direction of elongation of the axle 103 so as to define a plurality of adjacent sections 1 10a, 1 10b, 1 10c, 1 10d, 1 10e, 1 1 Of, 1 10g, 1 1 Oh, 110i, 1 10 j and 1 10k. In the present embodiment the plates 112a... 1121 are equally spaced such that each section has substantially the same volume, although in alternative embodiments the plates 1 12 may be spaced at varying intervals along the axle 103. In the present embodiment, the plates have a 400mm diameter and the axle 103 is 2m in length. As more clearly shown in Figure 4, each plate 112a... 1121 defining a section 1 10a... 1 10k is an incomplete annulus in plan view. In other words, each plate 1 12a...1 121 has a substantially circular profile and comprises an aperture 1 17 extending radially from the circumference of the plate towards its centre. The aperture provides a pathway for chicken breasts to pass from section to section upon rotation of the axle 103 (explained below).

As seen in Figure 4 and Figure 6B, adjacent plates 1 12a... 1121 are mounted 180° out of phase with each other such that the apertures 1 17 of adjacent plates 1 12a...1 121 extend from the centre to the circumference of their respective plates in opposing directions.

Each section 1 10a... 1 10k of the marinating apparatus has a respective guide member 1 15a, 1 15b, 1 15c, 1 15d, 1 15e, 1 15f, 1 15g, 1 15h, 1 15i, 115 j and 1 15k, as clearly seen in Figure 5. The guide members will now be described in more detail with reference to section 1 10a and corresponding guide member 1 15a as illustrated in Figure 4. The section 1 10a comprises a first plate 1 12a proximal to the supply part 107 and a second plate 1 12b proximal to the discharge part 109. The guide member 1 15a extends between the first and second plates. The first plate comprises first aperture 1 17a and the second plate comprises second aperture 117b.

The guide member 1 15a is substantially a curved parallelogram in plan form and comprises a first part 120 and a second part 124 which are integrally formed. The guide member 1 15a is connected at its second part 124 to an edge of the second aperture 1 17b of the second plate 112a, and extends to a planar part of the first plate 112a, to which it is connected at its first part 120. The planar part is typically the major surface of the first plate 1 12a. The first part 120 is connected to the first plate 1 12a at a location opposing the edge of first aperture 1 17a corresponding to that of the edge of second aperture 1 17b to which the second part is connected. Here, by "corresponding edges", it is meant the edges that would be in the same plane if each plate 1 12 was rotated to the same orientation. By extending in this direction, the guide member is substantially adjacent the axle 103 along the length of the guide member 1 15a.

The angle a subtended between the plane of the second plate 1 17b and the guide member 1 15a (the "angle of attack") in the present embodiment is 44°. However, it will be appreciated that other angles of attack may be used. The chosen angle will depend on the weight of items being processed, portion size and the number of portions per minute required. The angle a will typically be chosen to be in the range 40-60° and in a particularly preferred arrangement is substantially 44°.

The guide member 1 15a is connected to the first plate 1 17a via two protruding ears 121 thereby forming a gap 122 between the first part 120 of the guide member 1 15a and the first plate 1 12a. The second part is connected to the edge of second aperture 117b along the full width of the second part 124. Further, the longitudinal edge of the guide member 1 15a proximal to the axle is curved in the same orientation as the axle thereby forming a gap 1 16 between the guide member 1 15a and the axle 103. This gap 1 16 is clearly seen in Figures 5, 6a and 6b, which show guide members 115k and 1 15j. The longitudinal edge of the guide member 1 15a proximal to the trough is also curved so as to cooperate with the curved surface of the trough 101. The diameter of the plates 112a... 1 12I is substantially equal to that of the trough such that the guide members substantially abut the inner surface of the trough. There is a small gap between the guide members and the inner surface of the trough however, in order to allow marinade to flow between sections and to prevent blockages.

Further, in addition to apertures 1 17, each plate 112a... 1121 comprises second 1 13a and third 1 13b apertures adjacent the axle as seen in Figures 6A and 6B. The second and third apertures are smaller than aperture 1 17 and are located on the opposing side of the axle 103 to that of aperture 1 17. Marinade is sprayed into the marinating apparatus from a marinade spender "volume filler" device (not shown) located above the marinating apparatus. Preferably the marinade spender or dosing apparatus comprises a number of outlets (such as nozzles) corresponding to the number of sections, and marinade is introduced into each section separately so as to coat the axle 103, plates 1 12a....1 12I, guide members 1 15a... 1 15k and base of the trough 101. As the chicken breasts are transported through the marinating apparatus, they are then coated in the marinade within the marinating apparatus.

As seen in Figure 1A, the marinating apparatus is inclined at an angle Θ from the horizontal, with the discharge part 109 being higher than the supply part 107. The angle Θ is preferably less than 12.5°, and most preferably equal to 9°. An angle Θ of 9° has been seen to provide the best "tumbling" (i.e. turning or "flipping" of chicken breasts between the sections) as the chicken breasts were transported along the marinating apparatus from the supply part to the discharge part and thereby good marinade coverage. In other embodiments the marinating apparatus may be horizontal, i.e. Θ =0°. The choice of the inclination angle Θ, the angle of attack a and the rotational speed of the axle will be chosen according to the product to be handled so as to achieve good marination, no splitting of product, and reasonable process time.

In the arrangement of Figure 2 to 6A, the axle rotates clockwise when viewed from the supply part 107, as illustrated by arrow A in Figure 4. Typically, the axle is rotated at a speed in the range 40-100 revolutions per minute. Chicken breasts fed into the supply part 107 will rest on the base of the trough 101. Due to the rotation of the axle, the guide member 1 15 within the supply part will guide the chicken breast through the aperture 1 17 in the plate 112a of the supply part proximal to the discharge part 109. The chicken breasts will now be located in section 1 10a and, similarly, due to the arrangement of the guiding members and the rotation of the axle, the chicken breasts will be guided by guiding member 1 15a through the aperture 1 17 located in the plate 1 12b of section 1 10a proximal to the discharge part 109. This process repeats and the chicken breasts are transferred from the supply part 107 to the discharge part 109 through each of the sections 1 10a... 1 10k. The trough 101 comprises a discharge aperture (not visible in the view of Figure 2) through which the marinated chicken breast falls under gravity into its respective timing hopper, as discussed above with reference to Figure 1 A.

As the chicken breasts are passed from section to section, they are coated in marinade. Advantageously, the angle of attack of the guiding members means that as the chicken breasts are guided from one section to the next, they are turned over. This allows a more even coating of marinade on both sides of the chicken portions. This tumbling effect is enhanced if the apparatus is inclined at an angle but the apparatus could be oriented horizontally.

As a further advantage, the marinating apparatus of the present embodiment allows individual batches of chicken to remain separated as they are marinated. Specifically, a batch of four chicken breasts will be introduced into the supply part 107. When this first batch has been transferred from the supply part 107 to the first section 1 10a, a second batch of chicken breast is introduced into the supply part 107. In this manner, individual chicken breasts remain within their allocated batch and separate to other batches during the marinating process. This allows easy packing of the batches when they are discharged from the discharge part 109.

As a further advantage, because the batches remain separate and at known positions during the marinating process, this means that the weighing of batches can be carried out prior to marinating (as described above with reference to Figure 1A and 1 B). This allows the amount of chicken being packaged and distributed to be accurately controlled (as compared to processes when the chicken is weighed after being marinated), as the weight of marinade does not have to be taken into account during weighing.

The control system 150 is operable to control the rotation speed of the axle 103. Generally, as the rotation speed increases, throughput can be increased as more batches of chicken breast can be marinated per minute. However, the rotation speed is preferably low enough so that batches can be introduced separately into the supply part 107 of the marinating apparatus. Preferably, the rotation speed is 40 revolutions per minute (rpm) or 80rpm. Best results have been seen with an incline angle Θ of 9° and a rotation speed of 80rpm.